Studies on Cryogenic Treated Drills Under Nano-Fluid Based Reduced Quantity Lubrication Conditions for Machining Ti6Al4V

2018 ◽  
Author(s):  
D. Samuel Raj ◽  
Jerome Arul Praveen C. ◽  
Aarthi S. Kumaran
Keyword(s):  
Tool Wear ◽  
Cryogenic Treatment ◽  
Minimum Quantity Lubrication ◽  
Nano Particles ◽  
Limiting Factors ◽  
Cutting Fluids ◽  
Deep Cryogenic Treatment ◽  
Nano Fluid ◽  
The Coefficient Of Friction ◽  
Marginal Improvement

Minimum quantity lubrication (MQL) machining is gaining wide acceptance because of the need to make machining more environment friendly. With cutting fluids contributing more than 10–15% of the manufacturing costs, economics of MQL is also gaining interest. The initial cost of commercial MQL systems is one of the limiting factors hindering their adoption in small and medium scale industries. This study, uses a simple commercial paint sprayer with a portable compressor (with a total cost < $125) to produce an MQL like spray with a slightly higher flow rate as compared to MQL (and is thus called reduced quantity lubrication) in drilling Ti6Al4V. Tungsten carbide drills of 7 mm diameter were subjected to deep cryogenic treatment, which has been acknowledged as a means of improving tool wear resistance. There was a marginal improvement in drill microhardness as a result of cryogenic treatment. The performance of untreated and cryo-treated drills was compared for tool wear, hole surface roughness and cutting forces. In addition to the normal air-coolant mist, the effect of adding nano-particles in the coolant was also studied. It is found that cryo-treated drills under nano-fluid based reduced quantity lubrication (RQL) conditions performed better than untreated drills and conventional cutting fluids, in terms of all the three measured parameters. This can be attributed to the higher thermal conductivity of nano-fluid based coolants and their ability to reduce the coefficient of friction at the chip-tool interface.

Effect of tri-hybridized metallic nano cutting fluids in end milling of AA7075 in minimum quantity lubrication environment

2021 ◽  
pp. 095440892110037
Author(s):  
S Vignesh ◽  
U Mohammed Iqbal
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
End Milling ◽  
Coconut Oil ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Nano Particles ◽  
Cutting Fluids ◽  
Minimum Quantity ◽  
Nano Fluids

The current paper is concentrated on the mechanical and machining process exploration of metallic nano-lubricant with the concept of tri-hybridization with improved lubricative and cooling properties by using TiO2, ZnO and Fe2O3 metallic nano particles with neat cold-pressed coconut oil in a fixed volumetric proportion (10:90). End milling of gummy material like aluminium requires a solution to the conventional dry and wet machining due to high productivity requirement and to obtain good surface quality. So, the prepared nanofluids were tested for their rheological behavior and latter introduced into milling of AA7075 as a solution to the above stated problem. Overall, the nanofluids gave good performance when compared to conventional methods. Furthermore, the results obtained from the experiments confirm that the trio-hybridized lubricant has reduced the cutting force, tool wear and surface roughness in an improved way when related to monotype nano fluids. The response surface methodology is performed to evaluate the interaction of process parameters in minimum quantity lubrication environment with nano fluids. The results show that the cutting forces, surface roughness, tool wear was minimized while machining with hybrid cutting fluids and well within the desirability.

scholarly journals Effects of deep cryogenic treatment on WC-Co cutter performances in milling of superalloy GH536

2020 ◽  
Vol 12 (5) ◽  
pp. 168781402091849
Author(s):  
Dong Liu ◽  
Li Gao ◽  
Peng Zhou
Keyword(s):  
Tool Wear ◽  
High Performance ◽  
Cryogenic Treatment ◽  
Experimental Result ◽  
Deep Cryogenic Treatment ◽  
Machined Surface ◽  
The Poor ◽  
Machined Surface Quality ◽  
Milling Operation ◽  
Depth Analysis

GH536 has been widely employed as one kind of high-performance materials; however, the poor machinability of GH536 especially substantial tool wear can still be considered as a problem. On the contrary, deep cryogenic treatment can be considered as an effective heat treatment to improve the milling cutter performances. Considering few studies that investigated the deep cryogenic treatment of the WC-Co cutters, this article experimentally investigated the effects of deep cryogenic treatment on WC-Co cutter performances in milling of superalloy GH536. The detailed discussion in terms of the microhardness before milling, the cutting forces during milling, and the tool wear and the machined surface quality after milling operation were performed based on the in-depth analysis of the experimental result comparison between the deep cryogenic treatment and the conventional tools. Some key findings were given in the end to conclude this work.

Improvement of Tool Life of a Commercial Drill Bits by Cryogenic Treatment While Machining Widmanstatten Ti-6Al-4V.

2021 ◽  
Author(s):  
Abdullah Sert ◽  
Fatih Hayati ÇAKIR
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Cryogenic Treatment ◽  
Cutting Tools ◽  
Drill Bit ◽  
Deep Cryogenic Treatment ◽  
Drill Bits ◽  
Stereo Microscope

Abstract In this study, the performance of Ø 8 mm WC-Co (10%) drill bits with a TiAlN coating was tested for machining of Ti6Al4V alloy with a Widmanstatten structure. In order to improve the tool life, cutting tools were subjected to deep cryogenic treatment. In total, three groups of tools were prepared for this study. The first group was used for reference as the supplied state; the second group was subjected to 24 hours deep cryogenic treatment at -196 ° C, and the third group was subjected to 24 hours deep cryogenic at -196 ° C, additionally was tempered 2 hours at 200 ° C. Machining experiments were done by drilling and a set of 60 holes were drilled with each drill bit, and tool wear were observed and recorded with a stereo microscope. Additionally, Scanning Electron Microscope (SEM) and Energy Dispersive Spectroscopy (EDS) analyses were carried on to understand the tool wear better. The microhardness of Cryo-treated and tempered cutting tools hardness increased up to 20 Hv (about 1%), and the toughness value did not change significantly. Cutting performance was observed by measuring the cutting forces during drilling experiments. According to these results, deep cryogenic treatment on WC-Co-based inserts decreased cutting forces by approximately 7% compared to the reference drill bit, which affected the cutting tool life. The dominant wear mechanism was Built-up edge (BUE) formation, and cryo-treatment lowered the BUE amount 8% and cryo-treated and tempered drill bit 45% compared to the reference drill bit.

Application of tri-hybridized carbonaceous nanocutting fluids in an end milling operation by the minimum quantity lubrication technique

2021 ◽  
pp. 135065012110438
Author(s):  
S. Vignesh ◽  
U. Mohammed Iqbal
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
End Milling ◽  
Hexagonal Boron Nitride ◽  
Coconut Oil ◽  
Minimum Quantity Lubrication ◽  
Work Piece ◽  
Cutting Fluids ◽  
Minimum Quantity ◽  
Milling Operations

This paper is concentrated on the exploration of carbonaceous nanocutting fluids with the concept of tri-hybridization with improved lubricative and cooling properties by using multi-walled carbon nanotubes, hexagonal boron nitride , and graphene nanoparticles with neat cold-pressed coconut oil in a fixed volumetric proportion. The rheological properties of the nanofluids were studied to assess their performance in real-time end milling operations using an AA7075 work piece on a CNC lathe machine under a minimum quantity lubrication environment. At the outset, the carbonaceous nanofluids gave good performance when compared to conventional cutting fluids. Furthermore, the surfaces of the tribo-pairs and the chips formed were analyzed using a profilometer and high-end microscopes. The results obtained from the experiments confirm that the tri-hybridized carbonaceous nanolubricant has reduced the cutting force, tool wear, and surface roughness when correlated to monotype nanofluids. The scanning electron microscope images of the surface and tool were studied and it was found that the surface quality was maintained while end milling with tri-hybridized carbonaceous nanofluid. Improvement of ∼17%, 20% and 25% in cutting forces, surface roughness and tool wear was found in tri-hybrid fluid when compared to other fluids. Thus, the present work indicates that the addition of carbon-based nanoparticles with coconut oil has offered better performance and is found to be a credible alternative to existing conventional cutting fluids.

Machinability investigation and sustainability analysis of minimum quantity lubrication–assisted micro-milling process

2020 ◽  
Vol 234 (11) ◽  
pp. 1388-1401
Author(s):  
Xueming Yang ◽  
Xiang Cheng ◽  
Yang Li ◽  
Guangming Zheng ◽  
Rufeng Xu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Sustainability Assessment ◽  
Minimum Quantity Lubrication ◽  
Production Quality ◽  
Milling Process ◽  
Micro Milling ◽  
Cutting Fluids ◽  
Thin Wall ◽  
Minimum Quantity

Machining conditions such as cutting fluids exert a crucial function in micro-milling, which removes chips from the cutting area and lubricates the interface between the tool and workpiece. Therefore, it is necessary to identify suitable cutting fluids for processing different materials. In this article, the effects of cutting fluids (dry, flood cooling, minimum quantity lubrication, and jet cold air) on tool wear, surface roughness, and cutting force were studied. The Pugh matrix environmental approach was used to compare different cutting fluids in terms of sustainable production. In addition, a curved thin wall was processed to demonstrate the value of minimum quantity lubrication in industry. The experimental results illustrated that the minimum quantity lubrication can not only effectively reduce tool wear and cutting force but also improve the finished surface quality. According to the sustainability assessment results, minimum quantity lubrication was superior to other cutting fluids in terms of environmental impact and production quality. The curved thin wall size error was only 2.25% under minimum quantity lubrication condition. This indicated minimum quantity lubrication was particularly suitable for micro-milling of H59 brass and 6061 aluminum compared to other cutting fluids.

scholarly journals Minimum Quantity Lubrication (MQL) and its Effect on Tool Wear During Miniature Drilling :an Experimental Study

2016 ◽  
Vol 1 (2) ◽  
pp. 65-70
Author(s):  
Norsalawani Binti Mohamad ◽  
Rubina Bahar
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
High Speed Steel ◽  
Minimum Quantity Lubrication ◽  
Limiting Factors ◽  
Work Piece ◽  
Machining Processes ◽  
Minimum Quantity ◽  
Tool Condition ◽  
Overall Performance

Miniature drilling is widely used in industries including electronics and reconstructive surgeries to create small sized holes. Chip removal and effective supply of coolant are the two limiting factors that make the process more complex compared to other meso scale machining processes and also contribute to the tool wear. The tool wear in the process is mainly caused by the interaction, motion and chip production between the tool and work piece. Uniform supply of coolant must be ensured to reach the drilled cavity to keep the tool wear to a minimal level. This study includes experimental investigation of the tool condition after applying Minimum Quantity Lubrication (MQL) system as a greener approach as the name indicates. The tool condition with MQL has also been compared with dry and flood cooling. Two different types of drill bit materials (High Speed Steel and Carbide) have been tested under same experimental condition to drill through Aluminum Alloy 6061 and it has been found that overall performance in terms of tool condition after applying MQL was better compared to the other two methods. The overall wear propagation area was measured for both the conditions. It was seen, the wear propagation covered minimal area with MQL while for flood and dry condition wear was spread over a bigger area on flank. 

scholarly journals Experimental Investigation on Effects of MQL on Surface Finish and Tool Wear in Turning of SAE 1018

2018 ◽  
Vol 7 (2) ◽  
pp. 67-69
Author(s):  
Sandeep Kumar ◽  
Sukhpal Singh Chatha ◽  
Rutash Mittal
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Metal Cutting ◽  
Substantial Reduction ◽  
Minimum Quantity Lubrication ◽  
Environmental Safety ◽  
Work Piece ◽  
Cutting Fluids ◽  
Nose Radius ◽  
Machining Processes

In all machining processes, tool wear is a major problem and it leads to tool failure. In metal industries, the use of cutting fluids affects both employee’s health and environmental pollution. But the use of cutting fluids becomes necessary to keep tight tolerances and to maintain the work-piece surface properties without damages. Researchers are trying to reduce the use of coolant lubricant fluids in metal cutting to obtain environmental safety. So, to minimize the use of cutting fluids new cutting techniques are investigated. Minimal quantity of Lubrication (MQL) is a recent technique introduced in machining to obtain less tool wear and environment safety. The minimum quantity lubrication was provided with a spray of mixture of air and vegetable oil at suitable pressure. MQL machining was performed much superior compared to dry and wet machining due to substantial reduction in tool wear and cutting zone temperature and a better surface finish. MQL provides neat and clean environment avoiding health hazards due to smoke, fumes and gases etc. In this study work-piece of SAE 1018 were prepared to investigate their Surface finish under turning with coated tool bits. Wear of nose radius of tool bits were analyzed by SEM which results in less wear in MQL process as compared to flood cooling.

scholarly journals Application of Eco-Friendly Cutting Fluids Through Small Quantity Lubrication Technique: A Study

2018 ◽  
Vol 7 (2) ◽  
pp. 116-120
Author(s):  
Amrit Pal ◽  
Hazoor Singh Sidhu
Keyword(s):  
Minimum Quantity Lubrication ◽  
Colloidal Suspensions ◽  
Nano Particles ◽  
Cutting Fluid ◽  
Superior Performance ◽  
Cutting Fluids ◽  
Machining Performance ◽  
Machining Processes ◽  
Minimum Quantity ◽  
Nano Fluids

Owing to environmental concerns and growing regulations over contamination and pollution, the demand for renewable and biodegradable cutting fluids is rising. The aim of this paper is to review the eco-friendly and user-friendly minimum quantity lubrication (MQL) technique using vegetable-based oil and solid lubricant in different machining processes. It has been reported in various literature that the minimum quantity lubrication (MQL) method using vegetable oil-based cutting fluid shows superior performance as compared to dry and wet machining. The major benefits of MQL are reduction of consumption of cutting fluid, cost saving, reduction of impact to the environment and improved overall performances in cutting operation and the surface quality. To achieve improved thermal conductivity researchers focused attention on nano fluids. Nano fluids are nano-metered sized colloidal suspensions in the base fluid like water, oil, glycol, etc. The application of nano fluid controls the tool wear by reducing the temperature. Impingement of the nano-particles with high pressure in MQL enables entry of nano-particles at the tool chip interface. Thus it reduces the coefficient of friction and improves machining performance significantly.

scholarly journals Performance Evaluation of MQL with Graphene Mixed Nano Fluids prepared at different Concentrations in Turning of Pure Titanium (TI6Al4V) Alloy

2021 ◽  
Vol 309 ◽  
pp. 01041
Author(s):  
S. Suresh ◽  
N. Sateesh ◽  
Ramsubbiah ◽  
B. Ch Nookaraju ◽  
D. Sivanagaraju ◽  
...  
Keyword(s):  
Experimental Design ◽  
Minimum Quantity Lubrication ◽  
Ti6al4v Alloy ◽  
Cutting Conditions ◽  
Nano Particles ◽  
Cutting Fluids ◽  
Machining Parameters ◽  
Minimum Quantity ◽  
Mql System ◽  
Nano Fluids

This paper presents an investigation into the minimum quantity lubrication mode with Nano fluid during turning of titanium (TI6AL4V) alloy. In heavy cutting conditions, minimum quantity lubrication (MQL) has been observed, that, Nano-cutting fluids which have enrich thermal conductivity than base fluid, are begun to be used in MQL system. The addition of the required nano particle ratio to the base liquid is one of the most important issues that arise in this method. Therefore, this study aimed to find the optimum distribution rate of graphene nano particles having excellent properties and machining parameters. To do this, graphene nano particles were added to a vegetable-based cutting solution. Nano-cutting fluids were prepared in different volumetric concentrations. When turning of titanium (TI6AL4V) alloy, these Nano fluids were used in the MQL system. Three different parameters were added to the experimental design to study the performance of Nano fluids under several cutting conditions. i.e., speed, feed rate and depth off cut. Apart from this experimental design, three tests were carried out at each concentration ratio while keeping the machining parameters constant to clearly see the impact of concentration rates on surface roughness, flank wear. And crater wear. In addition, while chipping/fracture, were observed under all cutting conditions

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